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Turboden ORC technology for the wood industry
Doc.: 15-COM.P-12-rev.0
Update: 01/06/2015
12
Wood –technology Conference June 1
-2
2015, Opatija, Croatia
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• What the ORC is • ORC reference plants
• District heating • Pellet Industry • Tri-generation
• Why Turboden ORC • Innovation in ORC
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Today’s topics
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Turboden solutions from 200 kW to 15 MW electric per single unit
electricity
heat
Biomass
Heat recovery
Geothermal
Solar
What the ORC is
Turboden designs, develops and maintains turbogenerators based on the Organic Rankine Cycle (ORC), a technology for the combined generation of electric power and heat from various renewable sources, particularly suitable for distributed generation.
Waste to energy
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Organic Rankine Cycle: Thermodynamics
The turbogenerator uses the heat carrier (e.g. hot temperature thermal oil) to pre-heat and vaporize a suitable organic working fluid in the evaporator (8→3→4). The organic fluid vapor powers the turbine (4→5), which is directly coupled to the electric generator through an elastic coupling. The exhaust vapor flows through the regenerator (5→9) where it heats the organic liquid (2→8). The vapor is then condensed in the condenser (cooled by the water flow or other) (9→6→1). The organic fluid liquid is finally pumped (1→2) to the regenerator and then to the evaporator, thus completing the sequence of operations in the closed-loop circuit.
Turbine
Generator
Pre-heater
Cooling medium
Condenser
Evaporator
Pump
Heat carrier
Electric Energy
Tem
pera
tur
e
Entropy
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ORC provides significant advantages as compared to steam
Steam Rankine Cycle
Tem
pera
ture
Entropy
Tem
pera
ture
Entropy
Organic Rankine Cycle (ORC)
• High enthalpy drop • Superheating needed • Risk of blade erosion
• Small enthalpy drop • No need to superheat • No supercritical pressure • No risk of blade erosion
Thermodynamic features and
consequences
• Water treatment required • Highly skilled personnel needed • High pressures and temperatures in the
cycle
• Non-oxidizing working fluid with no corrosion issues
• Minimum personnel and O&M (1) • Completely automatic (2) • No blow down
Operation and maintenance costs
• Convenient for large plants and high temperatures
• Low flexibility with significantly lower performances at partial load
• High flexibility and good performances at partial load
• High availability (average >98%) • Possibility to work at low temperatures
(90+
C)
(1) Standard maintenance: 2-3 days per year (2) Fast start-stop procedure (ca. 20 min), partial load operation (down to 10% of nominal load)
Other features
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Flexible and automatic
ORC Partial Load Efficiency
One of the key
points in the
success of
ORC
technology is
the capability to
adapt to load
variation easily
and quickly ’’
‘‘
Design Point
Cooling water temperature effect on cycle efficiency
Actual Load / Nominal Load
Gro
ss e
lect
ric e
ffici
ency
Water outlet temperature from condenser [
C]
Part load operation down to 10% of nominal load. Mantains 90% of cycle efficiency down to 50% of loading
Turboden ORC units automatically adapt the cycle at the ambient temperature variations
OR
C A
ctua
l Effi
cien
cy /
OR
C N
omin
al E
ffici
ency
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How an ORC plant works
Heat source
Organic Rankine
Cycle
Heat exchanger
Heat rejection system
Biomass furnace Hot streams from industrial processes Gas turbines Internal combustion engines Geothermal source …
Direct exchange Heat carrier loop
• Thermal oil • Pressurized water • Saturated steam • …
Electric power (or mechanical)
Cooling towers Water cooled condensers Air cooled condensers …
Thermal users Industrial process District heating Absorption chiller …
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District Heating Networks - schema
WITHOUT ORC
WITH ORC
HEAT USER
BIOMASS POWERED
BOILER BIOMASS
hot water
cold water
HEAT USER
BIOMASS cold water
hot water
BIOMASS POWERED
BOILER
Thermal oil
Electric power
ORC
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District Heating Networks – reference plant
Context / Special Feature
District heating - Hospital thermal user: 9.5 GWhth/year
Pellet Plant under construction - Pellet production capacity: 4 t/h
Model: Turboden 10 CHP Split Client: Rinnova Energia Start-up: August 2014 Location: Sospiro - Italy Fuel: Wood chips Electrical production: 999 kWe Thermal use: hospital Thermal power: 4000 kWth Water temperature: 65 - 85
C Boiler supplier: Uniconfort
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Sawmills
hot water
SELECTION
DRYING
TRUNKS
PRODUCT
bark sawdust
BARKING PROCESSING
cold water
PACKAGING
Thermal oil BIOMASS
POWERED BOILER
ORC
Electric power
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Sawmills – reference plant
Context / Special Feature
Timber drying kilns - capacity: 3.6 t/h – 30.000 t/year
Model: Turboden 18 CHP Split Client: Vrbovsko Eko Energija d.o.o. Start-up: August 2015 Location: Vrbovsko - Croatia Fuel: Wood chips Electrical production: 1862 kWe Thermal use: timber drying kilns Thermal power: 7800 kWth Water temperature: 60 - 90
C Boiler supplier: Polytechnik
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Wood Pellet Production - schema
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BELT DRYER
Pellet PELLET
READY TO BE PACKAGED
Suitable granulometry
UR 40%
UR < 13%
BIOMASS POWERED
BOILER
SELECTION/ SORTING
CHIPPING BARKING
AIR COOLING/ DEDUSTING
PELLET MAKING PRESS
ORC
DEDUSTING/ SELECTION/
REFINING
MILLING
Thermal oil
Electric power
TRUNKS
cold water
hot water
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Wood Pellet Production – reference plant
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Context / Special Feature
Pellet production process - Max pellet production: 6t/h - Hot water to dry saw from 50% to 10% Application Pellet - Biomass boiler: 6 kWth - Cogeneration with ORC: 4 kWth 999 kWe (brut); 950 kWe (net) - Pellet system supplier: Kahl
Model: Turboden 10 CHP Split Client: Pelet Grupa d.o.o. Start-up: February 2014 Location: Novska - Croatia Fuel: Wood chips Electrical production: 999 kWe Thermal use: drying belt in pelletisation process Thermal power: 4000 kWth Water temperature: 60 - 80
C Boiler supplier: Kohlbach
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CCHP – Combined Cooling Heating Power
cold water
ABSORPTION CHILLER
hot water
ELECTRIC POWER
DISTRICT HEATING
cold water
COOLING SYSTEM
BIOMASS POWERED
BOILER
BIOMASS
ORC
Thermal oil
USE IN PUBLIC BUILDING, HOTEL, …
Large public buildings – airports, shopping centers, etc. - can exploit hot water 24/7!
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CCHP – Combined Cooling Heating Power – reference plant
Context / Special Feature Heathrow - London main airport • The airport achieving the Carbon Trust Standard Company • Space Area: 20 000 m2, 100 000 m3 • Thermal power: 75% heat and 25% to chiller • Thermal usage: heat and cooling to Terminals T2a and T2b and heat
only to Terminal T5 • Reason for Tri-generation: biomass-fuelled combined cooling and
heating (CCHP) power plant, reducing the building’s carbon footprint of the airport overall, by at least 40 percent, by using renewable sources of energy.
Specificity CCHP - Fuel: biomass - Type of biomass: waste clean wood - Boiler supplier: VAS - Thermal oil boiler capacity: 9,790 kW - Cogeneration through ORC - Cooling power produced by chiller - Chiller supplier: HETCo Energy management due to: Photovoltaic Solar panels, rain water harvesting system reuses 85% of all the rainwater that falls on the Terminal 5 site, recycling or composting 70% of its waste by 2020.
ORC characteristics Model: Turboden 18 CHP Split Client: Morgan Sindall plc Start-up: May 2014 Location: Heathrow, London, UK Electric power generated: 1,862 kW Thermal power application: space heating/cooling Thermal power generated: 7,851 kW Water temperature: 55 - 95
C
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Turboden Reference Plants in Croatia
Pelet Groupa - Novska
Startup 2014
ORC 10 CHP Split
Power 999 kWe
Water temp. 60 – 80 °C
Description Pellet production plant
Spin Valis - Pozega
Startup 2015
ORC 14 CHP Split
Power 1450 kWe
Water temp. 60 – 80 °C
Description Sawmill / wood drying
Lika Energo Eko - Ubdina
Startup 2012
ORC 10 CHP Split
Power 999 kWe
Water temp. 60 – 80 °C
Description Pellet production plant
PANA - Turopolje
Startup 2015
ORC 10 CHP Split
Power 999 kWe
Water temp. 60 – 80 °C
Description Sawmill
Vrboscsko Eko Energija - Vrbovsko
Startup 2015
ORC 18 CHP Split
Power 1862 kWe
Water temp. 60 – 90 °C
Description Timber drying kilns
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About Turboden Turboden is a leading European company in development and production of ORC (Organic Rankine Cycle) turbogenerators. This state of the art equipment generates heat and power from renewable sources and heat recovery in industrial processes. The company was founded in 1980 in Milan by Mario Gaia, Associate Professor at Politecnico di Milano, teaching Thermodynamics, Renewable Energy and specifically studying ORC systems. At present Prof. Gaia is Honorary Chairman. A number of his former students are key persons in the Company and the whole Company is permeated by innovative and research oriented spirit. Turboden has always had a single mission: to design ORC turbogenerators for the production of heat and electrical power from renewable sources, while constantly striving to implement ORC technical solutions. In 2009, Turboden became part of UTC Corp., a worldwide leader in development, production and service for aero engines, aerospace drive systems and power generation gas turbines, to develop ORC solutions from renewable sources and waste heat worldwide. In 2013 UTC exits the power market forming strategic alliance with Mitsubishi Heavy Industries. In 2013 Mitsubishi Heavy Industries acquires from UTC Pratt & Whitney Power Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden S.r.l. and PW Power Systems, Inc. are MHI group companies to provide a wider range of products and services for thermal power generation systems. In 2013 Turboden’s Quality Management System gets certified to ISO
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1980 - Founded by Mario Gaia, professor at Politecnico di Milano
1998 – First ORC biomass plant in Switzerland (300 kW)
1990’s – First ORC projects in solar, geothermal and heat recovery applications
2000‘s - ORC biomass plants in Europe
2009 - United Technologies Corp. (UTC) acquires the majority of Turboden’s quotas. PW Power Systems supports Turboden in new markets beyond Europe. 100 plants sold
Today - Over 300 plants in the world, 240 in operation, 200 employees, ∼100 M€ turnover (2012)
2013 - MHI acquires the majority of Turboden. Italian shareholders stay in charge of management
35 Years of Experience
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Turboden – a Group Company of MHI
Mitsubishi Heavy Industries is one of the world's leading heavy machinery manufacturers, with consolidated sales of over $32 billion (in fiscal 2013). Foundation July 7, 1884
Energy & Environment
Providing optimal solutions in the energy-related
fields of thermal power, nuclear energy and renewable energy in
different environmental areas and for chemical plants & other
industrial infrastructures elements.
Commercial Aviation & Transport Systems
Delivering advanced land, sea and air
transportation systems, including civilian aircraft,
commercial ships and transit networks.
Machinery, Equipment & Infrastructure
Providing a wide range of products that form the foundation
of industrial development, such as machine tools, material
handling, construction machinery, air-conditioning and
refrigeration systems.
Integrated Defense & Space Systems
Providing advanced land, sea and air defense systems,
including naval ships, defense aircraft, launch vehicles and
special vehicles, as well as space-related services.
Energy & Environment
the largest segment of MHI over $12 billion (in fiscal 2013)
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20
Turboden ORC Plants in the World
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Innovation in Biomass Application
Regulatory changes EU regulation ask Member States to adapt their incentives for renewables: • The feed in tariff should be awarded only to plant below 500kW, • Plant within 1 MWe should benefit of a feed in premium additional to the electric
energy sell price to the electric grid • Larger plant should participate to bid process to receive feed in premium Turboden is working to provide performing solutions in a cost effective way also for 300kWe and 500kWe ORC CHP plants. Solution Direct Exchange between biomass combustion exhausts and ORC working fluid Targets • Reduce initial investment avoiding thermal oil circuit • Reduce building and civil works with outdoor solution • Reduce plant self consumption (no thermal oil pump consumption) and
increasing overall plant efficiency
Make a better business plan! Status • First reference plant in biomass under construction
(expected startup Dec. 2015) • Available from 2016
Thank you for your attention
Doc.: 15-COM.P-12-rev.0
Update: 01/06/2015
Francesco Campana Business developer
+39 335 6876370